Abstract: A tool system with a battery pack and a device that is configured to be selectively coupled to the battery pack. The battery pack has first, second and third pack terminals. The device has a battery mount with a body that defines a well and first and second device terminals. The body defines a well into which the battery pack is removably received. The first and second device terminals extend outwardly from a proximal portion of the battery mount and engage the first and second pack terminals when the battery pack is fully inserted into the well. At least one of the first and second pack terminals and the first and second device terminals is a male terminal that is received into a corresponding one of the first and second pack terminals and the first and second device terminals. A longitudinal axis of each of the first, second and third pack terminals is arranged parallel to a longitudinal axis of the battery pack.

Abstract: A method for forming an armature for an electric motor includes securing a lamination stack having slots therein on an armature shaft. A commutator is secured on one end of the armature shaft. Magnet wires are wound in the slots in the lamination stack and ends of the magnet wires are secured to the commutator. Plastic is molded around the lamination stack, commutator and magnet wires. Excess plastic is machined off. The magnet wires can have a layer of heat activated adhesive that is activated when the plastic is molded. Slots in the lamination stack can include slot liners formed of thermally conductive plastic. A fan can be formed when the thermally conductive plastic is molded to encapsulate the magnet wires.

Abstract: A system of cordless power tools includes a cordless power tool adapted to removably receive a rechargeable battery pack. The battery pack and the power tool can have complementary grooves and rails or L-shaped surfaces that aid in aligning the positive and negative blade terminals of the battery pack to the positive and negative tool terminals, respectively, of the power tool.

Abstract: A system of cordless power tools includes a cordless power tool adapted to removably receive a rechargeable battery pack. The battery pack and the power tool can have complementary grooves and rails or L-shaped surfaces that aid in aligning the positive and negative blade terminals of the battery pack to the positive and negative tool terminals, respectively, of the power tool.

Abstract: An armature for a brush commutated electric motor having a distributed coil winding arrangement for reducing brush arcing and electromagnetic interference (EMI). The winding pattern involves winding a first coil into a first pair of slots of the armature. A second coil having a first subcoil portion is then wound into the same slots as the first coil, while a second subcoil portion of the second coil is wound into a pair of slots that is offset by one slot position from the first pair of slots. The two subcoil portions have the same number of turns, and the total turns of the two subcoil portions equals the number of turns of the first coil. A third coil is then wound in the same slots as the second subcoil portion of the second coil. The third coil has the same number of turns as the first coil. This pattern is repeated around the armature.

Abstract: A battery pack 13 (FIG. 2) comprises an elongated cylindrical, metal casing 35, a plurality of cells 41, 43 in casing 35 and three coaxial pack terminals 46, 54, 61. For enhanced convenience, pack terminals 46, 54, 61 are electrically connectable in a cordless device 11 regardless of the angular orientation of the pack 13 about casing axis 33. To reduce cost and increase durability, pack 13 has no welded connections and will permit high current discharge rates. Cells 41, 43 are electrically connected but are mechanically disconnected. A spring 73 engages cell 41 and biases cells 41, 43 tightly together in compression to form good, low resistance electrical contact between cells 41, 43, casing base cap 45 and top 53. To provide a pack with two output voltages, the third pack terminal 61 has a polarity (relative to first pack terminal 46) the same as second pack terminal 54 and is electrically connected to the cell can terminal 43b of forward cell 43, thereby electrically by-passing cell 43.

Abstract: An electric motor has an armature and a stators. The armature has a lamination stack having slots therein. An internal shaft extends coaxially through the lamination stack. A plurality of magnet wires are wound in the slots of the lamination stack. A commutator is disposed on the armature shaft to which ends of the magnet wires are electrically coupled. The internal is shaft coupled to an external pinion and bearing journal by an insulated coupling. The magnet wires are at least partially encased in thermally conductive plastic. The magnet wires can have a layer of heat activated adhesive that is activated when the plastic is molded. Slots in the lamination stack can include slot liners formed of thermally conductive plastic. A fan can be formed when the thermally conductive plastic is molded to encapsulate the magnet wires. A power tool has the electric motor.

Abstract: A generator starting system utilizes a portable universal battery pack to start an internal combustion engine of the generator. The system is adapted to utilize any one of a plurality of universal battery packs having outputs of varying voltage. The generator can include a permanent magnet generator having first and second sets of windings. One set of windings generates AC power. The second set of windings is used to drive the PMG as an electric motor using power from the universal battery pack. In an embodiment, the system includes a brushless DC controller that electronically commutates the second set of windings to drive the PMG as a brushless DC motor.

Abstract: A generator system has two modes of operation, such as 120 VAC and 240/120 VAC. The generator system has a permanent magnet generator with two independent sets of windings that each generate a three phase AC voltage. One three phase AC voltage is coupled to a first cycloconverter and the second three phase AC voltage is coupled to a second cycloconverter. Live outputs of each cycloconverter are coupled to each other through a switch, such as a relay, and netural outputs of each cycloconverter are coupled to ground. A controller controls the cycloconverters to provide the modes of operation. In the 120 VAC mode, the switch across the live outputs of the first and second cycloconverters is closed, shorting the live outputs of the first and second cycloconverters together so that the live outputs are in parallel and the controller operates the first and second cycloconverters so their output voltages are in phase with each other.

Abstract: A generator system in accordance with the invention has two modes of operation, such as 120 VAC and 240/120 VAC modes of operation. The generator system has a permanent magnet generator with two independent sets of windings that each generate a three phase AC voltage. One three phase AC voltage is coupled to a first or master cycloconverter and the second three phase AC voltage is coupled to a second or slave cycloconverter. Live outputs of each cycloconverter are coupled to each other through a switch, such as a relay and neutral outputs of each cycloconverter are coupled to ground. A controller controls the cycloconverters to provide a first voltage, illustratively 120 VAC, across their respective outputs having the same amplitude.

Abstract: Magnet wires wound in slots in a lamination stack of a dynamoelectric machine are encapsulated, in whole or in part, with plastic. The plastic may be thermally conductive and have features molded therein that enhance heat transfer. The plastic may stiffen the armature and increase its critical speed. Characteristics of the plastic, its geometry and its distribution may be varied to adjust spinning inertia and resonant frequency of the armature. The magnet wires may be compressed into the slots, by application of iso-static pressure or by the pressure of the plastic being molded around them. Larger magnet wire can then be used which increases the power of the electric motor using the armature having the larger magnet wire. A two or three plate mold may be used to mold the plastic around the armature. Balancing features can be molded in place. The plastic can have a base polymer that is a blend of two or more polymers and various thermally conductive fillings.

Abstract: A system and method for reducing the cost of producing a brushless DC motor (58) is presented. The brushless DC motor (58) provides higher power density and efficiency with an increased tool run time. The brushless DC motor (58) includes a rotor assembly (72) that has an unmagnetized permanent magnet (74) affixed to a shaft. The permanent magnet (74) remains unmagnetized until the motor is partially assembled. A plurality of coils (94) for producing a magnetic field are wound about the rotor assembly (72). The coils (94) include end turns that enclose the rotor assembly (72) such that the rotor assembly (72) is not removable. Since the windings (94) are wound with the rotor assembly (72) already enclosed, the windings (94) do not require large end coils to allow subsequent insertion of the rotor (72). Minimizing the end coils reduces the length of wire required per turn, thereby reducing the resistance of the winding (94).

Abstract: A cylindrical magnet ring assembly having a cylinder magnet flux ring (102) formed with a plurality of inwardly projecting anchors (108); a plurality of permanent magnets (104), wherein the magnet can be formed with step portions (112) in the inner radial surface; a molded plastic member (106) being molded around the magnets and anchors to secure the magnets to a surface of the cylinder flux ring. There are several variations of the embodiments of the invention. Few embodiments are the following: in one aspect of the invention, magnets are inserted into magnet molded around an assembly ring (806) and the molded plastic secures the assembly ring to the flux ring; in another aspect, there are two assembly rings, a first assembly ring (is inserted into the one side of the cylinder flux ring then the second assembly ring is inserted into the other side of the cylinder flux ring and mated to the first assembly ring, after that the molded plastic secures the two assembly rings.

Abstract: A system of cordless power tools includes a cordless power tool adapted to removably receive a rechargeable battery pack. In each embodiment, the battery pack and the power tool have complementary rails and grooves that aid in aligning the positive and negative blade terminals of the battery pack to the positive and negative tool terminals, respectively, of the power tool. In one embodiment, a keying feature cooperates with a mating keying feature to further align the terminals of the battery pack to the terminals of the power tool. In a second embodiment, the battery pack includes two sets of blade terminals, with each set including a positive blade terminal and a negative blade terminal.

Abstract: A system and method for reducing the cost of producing a brushless DC motor is presented. The brushless DC motor provides higher power density and efficiency with an increased tool run time. The brushless DC motor includes a rotor assembly that has an unmagnetized permanent magnet affixed to a shaft. The permanent magnet remains unmagnetized until the motor is partially assembled. A plurality of coils for producing a magnetic field are wound about the rotor assembly. The coils include end turns that enclose the rotor assembly such that the rotor assembly is not removable. Since the windings are wound with the rotor assembly already enclosed, the windings do not require large end coils to allow subsequent insertion of the rotor. Minimizing the end coils reduces the length of wire required per turn, thereby reducing the resistance of the winding.

Abstract: Magnet wires wound in slots in a lamination stack of a dynamoelectric machine are encapsulated, in whole or in part, with thermally conductive plastic. Pre-formed features having a thermal conductivity higher than the thermally conductive plastic are insert molded when the plastic is molded. The pre-formed features may include a finned end cap and a fan. Alternatively, end domes of the plastic over end coils of the wound magnet wires have a metallic layer on them, such as by being metallized. The end domes can be formed with features which are also metallized. The thermally conductive plastic can have a phase change additive in it. The magnet wires can have a layer of heat activated adhesive that is activated when the plastic is molded. Slots in the lamination stack can include slot liners formed of thermally conductive plastic. A fan can be formed when the thermally conductive plastic is molded to encapsulate the magnet wires.

Abstract: A system of cordless power tools includes a cordless power tool adapted to removably receive a rechargeable battery pack. In each embodiment, the battery pack and the power tool have complementary rails and grooves that aid in aligning the positive and negative blade terminals of the battery pack to the positive and negative tool terminals, respectively, of the power tool. In one embodiment, a keying feature cooperates with a mating keying feature to further align the terminals of the battery pack to the terminals of the power tool. In a second embodiment, the battery pack includes two sets of blade terminals, with each set including a positive blade terminal and a negative blade terminal.

Abstract: A generator system in accordance with the invention has two modes of operation, such as 120 VAC and 240/120 VAC modes of operation. The generator system has a permanent magnet generator with two independent sets of windings that each generate a three phase AC voltage. One three phase AC voltage is coupled to a first or master cycloconverter and the second three phase AC voltage is coupled to a second or slave cycloconverter. Live outputs of each cycloconverter are coupled to each other through a switch, such as a relay and neutral outputs of each cycloconverter are coupled to ground. A controller controls the cycloconverters to provide a first voltage, illustratively 120 VAC, across their respective outputs having the same amplitude.

Abstract: A cylindrical magnet ring assembly having a cylinder magnet flux ring (102) formed with a plurality of inwardly projecting anchors (108); a plurality of permanent magnets (104), wherein the magnet can be formed with step portions (112) in the inner radial surface; a molded plastic member (106) being molded around the magnets and anchors to secure the magnets to a surface of the cylinder flux ring. There are several variations of the embodiments of the invention. Few embodiments are the following: in one aspect of the invention, magnets are inserted into magnet molded around an assembly ring (806) and the molded plastic secures the assembly ring to the flux ring; in another aspect, there are two assembly rings, a first assembly ring (is inserted into the one side of the cylinder flux ring then the second assembly ring is inserted into the other side of the cylinder flux ring and mated to the first assembly ring, after that the molded plastic secures the two assembly rings.

Abstract: Magnet wires wound in slots in a lamination stack of a dynamoelectric machine are encapsulated, in whole or in part, with thermally conductive plastic. Pre-formed features having a thermal conductivity higher than the thermally conductive plastic are insert molded when the plastic is molded. The pre-formed features may include a finned end cap and a fan. Alternatively, end domes of the plastic over end coils of the wound magnet wires have a metallic layer on them, such as by being metallized. The end domes can be formed with features which are also metallized. The thermally conductive plastic can have a phase change additive in it. The magnet wires can have a layer of heat activated adhesive that is activated when the plastic is molded. Slots in the lamination stack can include slot liners formed of thermally conductive plastic. A fan can be formed when the thermally conductive plastic is molded to encapsulate the magnet wires.